Apparatus and methods for large particle ash separation from flue gas using screens having semi-elliptical cylinder surfaces

ABSTRACT

Apparatus for separating ash particles from a flue gas. The apparatus includes a screen that has a plurality of semi-elliptical cylinder surfaces. The semi-elliptical cylinder surfaces having holes through which said flue gas flows and through which the ash particles will not pass. The screen has a single layer for performing the separation in a manner such that the ash particles fall away from the screen and collect outside of the screen. A method of reducing velocity of a flue gas passing through screening apparatus for separating flue gas from ash particles. The method includes replacing a first screen of the screening apparatus with a second screen that has a plurality of semi-elliptical cylinder surfaces.

CROSS-REFERENCE TO RELATED APPLICATIONS

This Application is a Divisional of U.S. patent application Ser. No.13/633,717, entitled Apparatus and Methods for Large Particle AshSeparation From Flue Gas Using Screens Having Semi-Elliptical CylinderSurfaces, filed Oct. 2, 2012, the disclosure of which is herebyincorporated herein by reference.

TECHNICAL FIELD

The present disclosure is related to the control of particulateemissions from industrial plants such as coal fired plants. Morespecifically, the present disclosure is related to the separation oflarge particle ash from flue gas utilizing screens.

BACKGROUND

Coal is a primary source of energy today and is commonly used as fuel toproduce electricity. A byproduct of producing electricity in a coalcombustion process is nitrous oxide (NOx), which is emitted with a fluegas from coal burning electrical generating plants. This nitrous oxideis considered a pollutant to the atmosphere. Catalytic reactors are usedto address this type of pollution by reducing the nitrous oxideconcentration in the flue gas. Ash is another byproduct of burning coaland typically comprises silicon dioxide, calcium oxide, carbon and manyother constituents depending on the makeup of the coal being burned. Thecombustion ash particles are usually small (up to 300 micro meters indiameter) and usually suspended in the flue gas. However, the combustionash particles can form large particle ash (LPA), which may have adiameter exceeding 1 centimeter. LPA formation can be traced tocombustion conditions in the boiler and clay like fly ash deposits onsuperheater tubes and backpass. The catalytic reactors are equipped witha plate or honeycomb-type catalyst and may have a pitch or openingranging up to 8 millimeters. LPA particles are larger than the catalystopening and therefore clogs up the catalytic reactor. As such, methodsfor separating ash from flue gas have been developed.

For example, U.S. Pat. No. 7,531,143, entitled “Arrangement forseparating coarse ash out of a flue gas stream,” discloses screens withpleated arrangements for separating ash particles from flue gas. Inpractice, these screens experience blockage in certain areas of thepleated arrangement, which creates high velocity zones that cause damageto the screens. As a result, these pleated screens have to be replacedfrequently or perform inefficiently and increase pressure drop in thesystem. It should also be noted that channels through which flue gasflows are large and, at least for this reason, screens used in thesechannels to separate ash from flue gas are also large and can berelatively costly.

U.S. Pat. No. 7,556,674, entitled “Method and device for the separationof dust particles,” discloses a system involving a baffle arrangementfor deflecting ash particles from the flue gas towards hoppers, whichcollect the ash particles. This system requires a long duct to settleout the ash particles. The length of the duct makes this systemrelatively expensive.

The pleated screen design and baffle arrangement utilizing gravimetricforces do not economically remove large particle ash. Another problem inthe art is that the ash particles in the flue gas erode structural ductmembers and separation screens. High flue gas velocities combined withhard ash particles will lead to significant metal wastage of thisequipment. In summary, existing systems and methods for screening ashparticles from flue gas are associated with high operating costs andhigh capital expenditure.

BRIEF SUMMARY

The current disclosure is directed to apparatus and methods forseparating ash particles from a flue gas using a screen having aplurality of semi-elliptical cylinder surfaces. According toembodiments, the semi-elliptical cylinder surfaces have holes throughwhich the flue gas flows and through which the ash particles will notpass. The semi-elliptical cylinder shape ensures a uniform velocityprofile at the screen surface. Further, the semi-elliptical cylindershaped screen arrangement allows for the strategic exposure of theinternal hole walls of the screen to the incoming ash and flue gas.Depending on the concave or convex configuration of the screen havingsemi-elliptical cylinder surfaces, more or less wall material is exposedto the ash particles. Furthermore, the semi-elliptical cylinder shapedscreen arrangement increases the surface area of the screen and reducesflue gas velocity at the screen surface and overall pressure drop overthe screen. Further yet, in embodiments, the semi-elliptical screenarrangement assures that a coated-surface of the screen is maximized inthe concave position of the screen thus extending the utilization lifeof the screen material.

Embodiments of the disclosure include methods of reducing the velocityof a flue gas passing through screening apparatus used for separatingflue gas from ash particles. The methods may include replacing a firstscreen of the screening apparatus with a second screen comprising aplurality of semi-elliptical cylinder surfaces. The semi-ellipticalcylinder surfaces have holes through which the flue gas flows andthrough which the ash particles will not pass.

The foregoing has outlined rather broadly the features and technicaladvantages of the present invention in order that the detaileddescription of the invention that follows may be better understood.Additional features and advantages of the invention will be describedhereinafter which form the subject of the claims of the invention. Itshould be appreciated by those skilled in the art that the conceptionand specific embodiment disclosed may be readily utilized as a basis formodifying or designing other structures for carrying out the samepurposes of the present invention. It should also be realized by thoseskilled in the art that such equivalent constructions do not depart fromthe spirit and scope of the invention as set forth in the appendedclaims. The novel features which are believed to be characteristic ofthe invention, both as to its organization and method of operation,together with further objects and advantages will be better understoodfrom the following description when considered in connection with theaccompanying figures. It is to be expressly understood, however, thateach of the figures is provided for the purpose of illustration anddescription only and is not intended as a definition of the limits ofthe present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention, reference isnow made to the following descriptions taken in conjunction with theaccompanying drawing, in which:

FIGS. 1A and 1B show a screen having a plurality of semi-ellipticalcylinder surfaces according to embodiments of the disclosure;

FIGS. 2A and 2B show a screen having a plurality of semi-ellipticalcylinder surfaces according to embodiments of the disclosure;

FIGS. 3A and 3B show a screen having a plurality of semi-ellipticalcylinder surfaces according to embodiments of the disclosure;

FIG. 4 shows a system for separating ash particles from flue gasaccording to embodiments of the disclosure;

FIG. 5A shows a prior art system for separating ash particles from fluegas;

FIG. 5B shows a prior art flat screen;

FIGS. 6A and 6B show flat screens;

FIGS. 7A to 7C show a semi-elliptical cylinder surface according toembodiments of the disclosure, and

FIGS. 8A to 8C show screens according to embodiments of the disclosure.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 5A shows prior art system 50 for separating large ash particlesfrom flue gas. Ash particles, as discussed herein are large and may beabout 1-2 centimeters in diameter. System 50 represents a typical coalfired power plant boiler arrangement. At boiler 500, coal is mixed withair (from preheater 505) and burned. The burning coal causes an increasein temperature in boiler 500 such that water injected into boiler 500 isvaporized to steam. As mentioned above, the burning coal produces ashparticles 105, which flows with hot flue gas 104 through duct 501. Duct501 leads to screen 506. Screen 506 has holes having a diameter suchthat flue gas is allowed to pass through screen 506. However, at leastsome ash particles are too big to pass through the holes of screen 506.Because these ash particles are too big to pass through the holes ofscreen 506, they accumulate in hopper 502. Flue gas passes throughscreen 506 and enters duct 503. Duct 503 channels flue gas 104 toSelective Catalytic Reduction (SCR) Catalyst 504, which removes nitrousoxide from flue gas 104. The flue gas 104 leaving SCR Catalyst 504 maythen be discharged into the atmosphere or cleaned further beforedischarge into the atmosphere.

Screen 506 is a pleated screen as known in the art and described forexample, in U.S. Pat. No. 7,531,143. After screen 506 has been inoperation for some time, ash particulate matter lodges in section 507 aof pleat 507 and blocks that section. This blockage may cause the fluegas to flow through triangular pleat 507 at a non-uniform velocity. Thisnon-uniform velocity can cause deterioration of screen material andrupturing of the screen. When this happens, particulate matter thatshould be screened passes through screen 506.

Screens that are essentially flat panels, such as flat screen 508 shownin FIG. 5B, do not have the problem described above with respect topleated screens. However, flat panel screens, such as flat screen 508,causes a high pressure drop in the order of 0.5 to 1 inch water column,as flue gas passes through it. This high pressure drop is consistentwith the high velocity at which flue gas flows through flat screen 508.

FIGS. 1A-3B show screens having a plurality of semi-elliptical cylindersurfaces according to embodiments of the disclosure. FIG. 1A showsscreen 10 having semi-elliptical cylinder surfaces 100-1 to 100-3. Inembodiments, screen 10 is made from a single layer of material such asmetal, plastic, composites and combinations thereof. Semi-ellipticalcylinder surfaces 100-1 to 100-3 have holes 101 that allow flue gas 104to flow through screen 10 but does not allow ash particles 105 to flowthrough screen 10. That is, ash particles 105 have a cross sectionalarea or a diameter that is greater than the cross sectional area ordiameter of holes 101, respectively. In embodiments, holes 101 have across sectional area of about 1 mm²-200 mm². Whatever the size of holes101, ash particles 105 are larger than holes 101. It should be notedthat, in practice, some ash particles are small enough to pass through,and do pass through, holes 101.

The flow of flue gas/ash particles mixture 104/105 to semi-ellipticalcylinder surfaces 100-1 to 100-3 and the screening of ash particles 105do not cause a buildup of ash particles, as occurs with respect to pleat507 of screen 506. For instance, screen 10 does not have an “apex shapedportion”—section 507 a that traps large ash particles. Furthermore, whenash particles 105 hit screen 10, screen 10's elliptical shape cause ashparticles 105 to fall away from screen 10 under the influence ofgravitational forces. In other words, screens as disclosed herein aredesigned to block the flow of large particle ash in a manner such thatthe ash particles collect in or on other equipment apart from thescreens. This is unlike filters, which are designed to trap particulateswithin the filter itself. Referring again to FIG. 1A, ash particles 105are collected away from screen 10 in, for example, a hopper. Becausescreen 10 is not designed to have a buildup of ash particles 105 on it,the velocity of flue gas across semi-elliptical cylinder surfaces 100-1to 100-3 (and screen 10 as a whole) is uniform.

In addition to not being susceptible to blockages, the shape ofsemi-elliptical cylinder surfaces 100-1 to 100-3 reduce the velocity offlue gas 104 by increasing the surface area of the screen as comparedwith the surface area of flat screen 508. The pressure drop may becalculated from the following formula:

ΔP=fv²

where f=friction factor and v=the velocity of the flue gas

In embodiments of the disclosure, screen 10 may also include screen sidesections 102. Sections 102 may also have holes 101 for separating ashparticles 105 from flue gas 104. In embodiments, screen side sections102 may be a solid plate without holes.

As can be seen from FIG. 1B, semi-elliptical cylinder surfaces 100-1 to100-3 have foci points 103-1 to 103-3 respectively. The foci points arethe points representing the focal line, based on the elliptical shape,at which light rays would focus (or substantially focus) when thesemi-elliptical surfaces are exposed to light if semi-ellipticalcylinder surfaces 100-1 to 100-3 are reflective. It should be noted,however, that this disclosure does not require reflective surfaces,which is mentioned here only to explain what is meant by focal point inthe context of elliptical shapes. Semi-elliptical cylinder surfaces100-1 to 100-3 may be any type of ellipse (e.g. a circle or a parabolicellipse). The type of ellipse will determine the exact location of focipoints 103-1 to 103-3. Notably, in the embodiment shown in FIGS. 1A and1B, flow direction F of flue gas/ash particular mixture 104/105 is fromthe side of screen 10 on which foci points 103-1 to 103-3 lie. In otherwords, FIGS. 1A and 1B show a concave configuration.

Screen 20 have the features of screen 10, except that, as shown in FIGS.2A and 2B, screen 20 has semi-elliptical cylinder surfaces 200-1 to200-3 with a convex configuration because foci points 203-1 to 203-3 areon the opposite side of flow F (i.e. flow of flue gas/ash particlemixture 104/105). The semi-elliptical convex shaped surfaces of screen20 are also not prone to blockages (thereby facilitating uniformvelocity distribution of flue gas 104) and has a higher surface areathan flat screen 508 (assuming screen 508 has the same perimeter asscreen 20). The higher surface area of screen 20 reduces flue gasvelocity as compared with flat screen 508. The perimeter of the screensillustrated herein is 2h +2w, where h is the height and w is the widthof the screens as illustrated in FIGS. 1A, 2A and 5B. For purposes ofdiscussion and comparison, all the screens described herein are assumedto have the same perimeter. In embodiments of the disclosure, screen 20may also include screen side sections 202. Sections 202 may also haveholes 201 for separating ash particles 105 from flue gas 104. Inembodiments, screen side sections 202 may be a solid plate withoutholes. It should be noted that any number of sides 202 may have holes ormay be a solid plate without holes. In embodiments, holes 201 have across sectional area of about 1 mm²-200 mm².

Screen 30, shown in FIGS. 3A and 3B, is a combination of the features ofscreen 10 (FIGS. 1A to 1B) with the features of screen 20 (FIGS. 2A and2B). FIGS. 3A and 3B show screen 30 having semi-elliptical cylindersurfaces 300-1 to 300-4. Screen 30 has both concave and convexsemi-elliptical cylinder surfaces. As shown in FIG. 3B, semi-ellipticalcylinder surfaces 300-1 to 300-4 have foci points 303-1 to 303-4respectively, which are on different sides of flow F (i.e. flue gas/ashparticle mixture 104/105). Semi-elliptical cylinder surfaces 300-1 to300-4 have holes 301 that allow flue gas 104 to flow through screen 30but does not allow ash particles 105 to flow through screen 30. That is,ash particles 105 have a cross sectional area or a diameter that isgreater than the cross sectional area or diameter of holes 301,respectively.

Again, screens with semi-elliptical surfaces in concave and convexorientation are not prone to blockages and facilitate uniform velocitydistribution of flue gas 104. Further, the surface area of screen 30 isrelatively larger than the surface area of flat screen 508, of screen 10and of screen 20, which all have the same perimeter. This larger surfacearea of screen 30 increases flue gas velocity as compared to flat screen508, screen 10 and screen 20. In embodiments of the disclosure, screen30 may also include screen side sections 302. Sections 302 may also haveholes 301 for separating ash particles 105 from flue gas 104. Inembodiments, screen side sections 302 may be a solid plate withoutholes. In embodiments, holes 301 have a cross sectional area of about 1mm²-200 mm².

FIG. 4 shows a system for separating ash particles from flue gasaccording to embodiments of the disclosure. System 40 shows a coal firedpower plant boiler arrangement. Boiler 400 (using air from preheater405) burns coal to produce steam as described above with respect toboiler 500. The ash produced by burning the coal flows with hot flue gas(as mixture 104/105) through duct section 401. Duct section 401 leads toscreen 10. Screen 10 is located across the lumen of duct section 401such that flue gas 104 has to pass through screen 10 to enter ductsection 403. In other words, screen 10 extends from wall to wall of theduct (401 and 403) such that there is screening across all of the lumenof the duct.

As described above, screen 10 has semi-elliptical cylinder surfaces100-1 to 100-3. Holes 101 of screen 10 have a diameter or crosssectional area such that flue gas 104 is allowed to pass through screen10 but ash particles 105 are too big to pass through holes 101 of screen10. Because ash particles 105 are too big to pass through holes 101, ashparticles 105 fall away from screen 10 and accumulate in hopper 402. Atthe same time, flue gas 104 passes through screen 10 into duct section403, which channels flue gas 104 to SCR Catalyst 404 (a destinationequipment). SCR Catalyst 404 removes nitrous oxide from the flue gas.Flue gas 104 is then discharged into the atmosphere or cleaned furtherbefore discharge into the atmosphere. In embodiments, screens 20 and 30can be used in system 40 instead of screen 10 or in addition to screen10. Any combination of screens 10, 20 or 30 may be used in embodimentsof the disclosure. Furthermore, screens 10, 20 and 30 may be used in asystem that includes other types of separation equipment, such as bafflearrangements, deflector plates, other types of screens and the like.

According to embodiments of the disclosure, the pressure drop in largeash particle separator systems may be reduced by using the screendesigns disclosed herein. For instance, flue gas velocity may be reducedby replacing a flat screen or a pleated screen, in the separator system(such as the system shown in FIG. 5), with a screen that includes aplurality of semi-elliptical cylinder surfaces, such as screens 10, 20,30 or combinations thereof. In embodiments, this change can produce areduction in flue gas velocity of about up to 20 percent and a reductionof pressure drop of about 40 percent. In embodiments, this change canproduce a reduction in flue gas velocity of about up to 40 percent and areduction of pressure drop of about 60 percent. In embodiments, thescreens as disclosed herein may be used to replace separation systemssuch as baffle based systems, deflector based systems, prior art screensystems and the like.

FIGS. 6A and 6B show flat screens 600. Flat screen 600 includeshexagonal shaped holes 602, formed by material M. Material M istypically a metal such as iron, aluminum, steel and the like. However,material M could also be plastic, ceramic composites and the like. Whenash particles hit material M of screen 600, they erode material M. Inorder for material to withstand the effect of processes (such asabrasion) brought about by ash particles hitting material M and the flowof flue gas 104 and particles (that are small enough) through holes 602,material M may be specially formulated or coated with other substancesso that it is resistant to these impacts. Specially formulating orcoating material M extends the life of screen 600. Material M has topsection 603 and internal section 604. Coating top sections 603 can bedone easily using a spraying device because these sections are fullyexposed. Internal section 604, however, has to be coated by the use of aspray device at an angle. For example, spray device 605, as shown inFIG. 6B, is positioned in a manner such that when material M is sprayedwith appropriate coating, the coating contacts section 604.

FIGS. 7A to 7C show screen 700 according to embodiments of thedisclosure. Screen 700, may also be made of material M and may have asimilar hexagonal structure as screen 600. However, in screen 700, thesehexagonal structures are in an elliptical cylindrical surface. When ashparticles hit material M of screen 600, they erode material M. To reducethis erosion, high efficiency ash removal systems must ensure uniformflow conditions as well as use high performance erosion resistantsurface treatments. Like screen 600, material M of screen 700 may bespecially formulated or coated with other substances so that it isresistant to these impacts. Specially formulating or coating material Mextends the life of screen 700. The coating material may include ceramicmetal composite.

FIG. 7C shows screen 700 and the views that FIGS. 7A and 7B represent.FIG. 7B is a view from the side where focal point 705 is located whileFIG. 7A is a view from the opposite side. Screen 700 has holes 702,which are similar to holes 602 shown in FIGS. 6A and 6B. In screen 700(FIG. 7A), however, internal sections 704 are more exposed than internalsections 604 because the bending of screen 700 into the semi-ellipticalcylinder shape pushes internal surface 704 outwards. In this way, screen700 presents a configuration in which it is much easier to coat internalsections 704 with a selected coating material than coating sections 604.

FIG. 7B shows screen 700 from the side of focal point 705. That is,internal sections 704 are less exposed than internal sections 604. Thus,if screen 700 is used in the concave configuration (i.e. flow of fluegas is from the side on which focal point 705 is located) less ofinternal sections 704 are exposed as compared to internal sections 604.Thus, in addition to making it easier to coat internal surfaces,configuring screens to have semi-elliptical cylinder surfaces candecrease the surface area that will be exposed to the effects ofabrasion from ash particles hitting screen 700. Consequently, in theconcave configuration shown in FIG. 7B, it might not be necessary toprovide any or as much coating of internal sections 704 as compared tothe internal coating needed for internal sections 604.

Therefore, for different applications of ash separation, a determinationmay be made as to which of the concave or convex semi-ellipticalcylinder designs is more efficient. For example, a determination may bemade whether the reduction in cost due to the ease of coating internalsections 704 outweighs the increased exposure of internal section 704 ifscreen 700 is used in a convex configuration. In sum, screens withsemi-elliptical cylinder surfaces provide flexibility in designingscreen separating systems.

The screens disclosed herein offer plants (that separate ash particlesfrom flue gas) much more versatility in designing flue gas/ash particleseparation systems as compared to traditional screens (e.g. flatscreens) and other separation mechanisms. For instance, by changing aflat screen of a particular perimeter to a screen with semi-ellipticalcylinder surfaces and the same perimeter as the flat screen, one canchange the screen surface area exposed to the flue gas/ash particlemixture.

Screens having both concave and convex semi-elliptical cylinder surfacesprovide a further benefit in the art. Specifically, in order to achievea particular surface area of screen, less depth is required for screenswith both concave and convex semi-elliptical cylinder surfaces. Thisfeature is illustrated by comparing FIGS. 8A and 8B with FIG. 8C. FIGS.8A and 8B show concave and convex orientation screens with depthdistance “d”. FIG. 8C shows a screen with both concave and convexorientation with depth “½d.” Thus, FIG. 8C provides the same surfacearea as FIGS. 8A and 8B with half the depth.

In sum, embodiments of the disclosure involves screens that are longerlasting and operates at a lower pressure drop, at lower velocity for theflue gas and with more uniform velocity distribution of the flue gas.Further, embodiments of the screens disclosed offers more versatility ascompared to traditional screens.

Although the present invention and its advantages have been described indetail, it should be understood that various changes, substitutions andalterations can be made herein without departing from the spirit andscope of the invention as defined by the appended claims. Moreover, thescope of the present application is not intended to be limited to theparticular embodiments of the process, machine, manufacture, compositionof matter, means, methods and steps described in the specification. Asone of ordinary skill in the art will readily appreciate from thedisclosure of the present invention, processes, machines, manufacture,compositions of matter, means, methods, or steps, presently existing orlater to be developed that perform substantially the same function orachieve substantially the same result as the corresponding embodimentsdescribed herein may be utilized according to the present invention.Accordingly, the appended claims are intended to include within theirscope such processes, machines, manufacture, compositions of matter,means, methods, or steps.

What is claimed is:
 1. A method of separating ash particles from a fluegas, said method comprising: flowing a flue gas and ash particle mixturevia a duct to a screen having a plurality of semi-elliptical cylindersurfaces, said semi-elliptical cylinder surfaces having holes throughwhich said flue gas flows and through which said ash particles will notpass, said screen having a single layer for performing said separatingin a manner such that said ash particles fall away from said screen andcollect outside of said screen, said screen being disposed in saidduct's lumen such that flue gas flows through said screen to adestination equipment via said duct.
 2. The method of claim 1 whereinsaid flue gas is flowed from a side of said screen on which foci pointsof said semi-elliptical cylinder surfaces lie.
 3. The method of claim 1wherein said flue gas is flowed from an opposite side of said screen onwhich foci points of said semi-elliptical cylinder surfaces lie.
 4. Themethod of claim 1 wherein said flue gas is flowed from a side of saidscreen that has foci points of some of said plurality of semi-ellipticalcylinder surfaces to a side of said screen that has foci points of otherof said plurality of semi-elliptical cylinder surfaces.
 5. The method ofclaim 1 further comprising: flowing said flue gas and ash particlemixture through a side section of each semi-elliptical cylinder surface,said side section having holes through which said flue gas flows andthrough which said ash particles will not pass.
 6. The method of claim 1wherein said holes of said screen comprises a cross sectional area ofabout 1 mm²-200 mm².
 7. The method of claim 1 further comprising:collecting said separated ash particles in a hopper.
 8. The method ofclaim 1 further comprising: after said separation, discharging said fluegas into the atmosphere.
 9. The method of claim 1 further comprising:after said separation, cleaning said flue gas further; and dischargingsaid cleaned flue gas to the atmosphere.